Structural member



1969 H A. BALINSKI STRUCTURAL MEMBER 4 Sheets-Sheet 1 Filed Dec. 30.1966 Fig. 3

S R m vmm NU U E L V N N 1 m A 0 L R08 m? H P S Aug. 19, 1969 H. A.BALINSKI STRUCTURAL MEMBER 4 Sheets-Sheet 2 Filed Dec. 30, 1966 Fig.4

INVENTOR.

HENRY A. BALI/VSK/ BY PE'NOLE'TO/V, NE'UMA/V .SE/BOLD 8 MLLMMS ATTORNEYS9, 1969 H. A. BALINSKI 3,461,638

STRUCTURAL MEMBER Filed Dec. 30, 1966 4 Sheets-Sheetv 3 INVENTOR HENRYA. aAu/vsk/ v BY PENDLEMMNEUMAN .SE/BOLD a w/LL/Aws A TTORNEYS Aug. 19,1969 H. A. BALINSKI 3,451,638

STRUCTURAL MEMBER Filed Dec. 30, 1966 r 4 Sheets-Sheet 4 INVENTOR.

HENRY A. BALM/SKI BY PE/VOLE TON, MEI/MAN SE/BOLD 8 WILLIAM-S A TTORIVEY5 United States Patent 3,461,638 STRUCTURAL MEMBER Henry A. ltalinslri,Hoffman Estates, 111., assignor to United States Gypsum Company,Chicago, 1th., a corporation of Delaware Filed Dec. 30, 1966, Ser. No.606,318 Int. Cl. E944: 3/30; E0411 1/00 U.S. Cl. 52-732 Claims ABSTRACTOF THE DISCLDSURE An elongated structural member comprising a web withat least one flange extending laterally from the web. At least one trusselement is struck from the web and the truss element extends laterallyfrom the Web and includes a portion disposed adjacent a distal portionof the flange to brace the flange.

This invention relates to structural members and particularly to beams,studs or trusses formed of sheet metal or like materials for use ascomponents in constructing walls, ceilings, floors and roofs.

One particular use for this invention is in studding support members forinterior building walls wherein wallboard panels are secured to metalstuds by driving selftapping rotary screw fasteners through the panelsand into or through flange portions of the studs, for instance asdisclosed in Nelsson et a1. United States Patent No. 3,056,234. A studcurrently in common use in such construction is a channel-type sheetmetal stud. However, there is a tendency for the flanges of this stud tobend and to be deflected inwardly away from a wallboard panel when aworkman attempts to drive fasteners through the flanges duringattachment of panels. This may prevent penetration of the fasteners intothe flanges. Thereupon, the usual course is to attempt to apply thefastener at another location, until a firm securement is made.

Another problem encountered is that the leading end or penetrating tipof the driven fastener may travel laterally over the flange from itsinitial point of contact and then penetrate the flange at a misalignedangle. Such problems of lack of securement and misalignment of thefastener often result in surface and core damage to the wallboard alongwith inadequate securement of the wallboard to the supporting studmember. In some cases the fasteners are not placed at desired locationsalong the wallboard because of the severe deflection of the metal studflange at a particular location. Where additional force is applied tothe fastener under the conditions of a deflecting flange, rotation andbending of the metal stud may result, as Well as strain and damage tothe wallboard. To overcome these problems, temporary lateral support isoften required to hold the flanges in place while the fasteners arebeing started. Another approach taken is the use of an excess quantityof fasteners. These problems necessitate additional finishing treatmentto wallboard surfaces which become marred, and interfere with effcientand economical construction of the most desired finished wallboardconstructions.

Various attempts have been made to overcome the aforementioned problems,including the design of sheet metal stud members having internal crossbracing, for instance as taught in my copending application Ser. No.359,867, filed Apr. 15, 1964, now US. Patent No. 3,349,- 535, and in thecopending application Ser. No. 499,939 of Frederick A. Thulin, filedOct. 21, 1965, now US. Patent No. 3,369,619.

It is an object of this invention to provide another solution to theaforementioned problems, and more specifi- 3,461,638 Patented Aug. 19,1969 cally to provide an improved light-weight structural member of theindicated type which will overcome the tendency of the flanges to bendunder laterally applied loads. It is another object of this invention toprovide an improved structural member of the indicated type which may beeconomically fabricated. It is a further object of this invention toprovide such an improved structural element which may be fabricated froma unitary blank of formable sheet material in substantially the samemanner and at substantially the same rate of production as thechannel-type sheet metal studs now in common use. Additional objects andadvantages of this invention will become apparent to those skilled inthe art from the description, accompanying drawings and appended claims.

In carrying out this invention in one illustrative form, an elongatedchannel-shaped member is fabricated from a sheet metal blank. Thismember includes a web section and a pair of spaced imperforate sideflanges extending from the opposite edges of the web. A series ofinternal reinforcing truss elements are struck and bent from the Web toextend laterally of the web beteween the two flanges. Each truss elementincludes a distal end section of a width substantially equal to thedistance between the distal edges of the side flanges. The distal edgeof each truss is disposed generally normal to the side flanges and maybe formed with a reinforcing edge: flange to enhance its compressive orcolumn strength. The distal edges of the truss elements also may be ininterlocking engagement with suitably formed lips on the distal. edgesof the side flanges. The openings formed in the web by striking out thetruss elements may serve as passages for wiring, conduits or the like.

For a more complete understanding of this invention, reference shouldnow be had to the examples illustrated in the drawings wherein:

FIG. 1 is a fragmentary perspective view of a partition constructionincluding a stud employing teachings of this invention;

FIG. 2 is a perspective view of a portion of a stud according to FIG. 1;

FIG. 3 is a cross-sectional view through a stud according to FIG. 1 in apartition construction, showing stages of attachment of wallboard panelsthereto;

FIG. 4 is a plan view of a portion of a sheet metal blank cut to form astructural member such as the stud of FIG. 1;

FIG. 5 is a perspective view of a portion of another stud employingteachings of this invention;

FIG. 5a is an enlarged detailed view of a modified interlockingarrangement between a truss and the side flanges in the stud of FIG. 5;

FIG. 6 is a perspective view of a portion of another stud employingteachings of this invention;

FIG. 7 is an end view of the stud of FIG. 6;

FIG. 8 is a perspective view of a portion of another stud employingteachings of this invention;

FIG. 8a is an enlarged detailed view showing the interlockingarrangement between a truss and the side flanges in the stud of FIG. 8;

FIG. 9 is a perspective view of a portion of another stud employingteachings of this invention;

FIG. 10 is an end view of the stud of FIG. 9;

FIG. 11 is a perspective view of a portion of another stud employingteachings of this invention;

FIG. 12 is an end view of the stud of FIG. 11; and

FIG. 13 is a plan view illustrating the pattern for formation of thetrusses of the stud of FIG. 11.

Referring now to the drawings and more particularly to FIG. 1, a stud 20is illustrated as being supported in a vertical position and having awallboard panel 22 secured thereto by a plurality of fasteners 24. Thefasteners may be self-tapping rotary screw fasteners such as aredisclosed in United States Patent No. 3,056,234, and which are driventhrough the panel and through the underlying flange 26 of the stud 20.

As also seen in FIGS. 2 and 3, the stud 20 comprises an elongated web 28and a pair of spaced, opposed, generally parallel, elongated sideflanges 26 and 30. The flanges are integral with the respective sideedges of the web 28 whereby the web and flanges form the channel-shapedelement. Each flange 26 and 30 is formed with a lip portion or returnflange along its distal edge, as illustrated. This lip portion on flange26 comprises a lateral section 32a and a return portion 34a, while thecorresponding parts of the lip portion on flange 34] are identified bynumerals 32b and 34b, respectively. Internal reinforcing truss elements36 are struck from the web portion 28 at spaced locations along thelength of the structural element 20 and are bent about their lines ofattachment to the web 28, as at 38, to positions between the flanges 26and 30 as illustrated. The truss elements 36 are disposed parallel toone another and perpendicular to the plane of the web portion 28 and tothe planes of the side flanges 26 and 30.

Each truss element 36 is of a generally T-shaped configuration,including a body portion comprising a relatively narrow section 40extending from the web 28, at hinge line 38, to a wider section 42 whichin turn merges into a distal edge or bracing section 44. Bracing section44 includes arms 46 and 48 which extend outwardly to points adjacent theinner surfaces of the respective flanges 26 and 30 near the outer ordistal edges of these flanges. The section 44 is of a width slightlyless than the spacing between the flanges 26 and 30 whereby the outerends of arms 46 and 48 are spaced from the inner surfaces of theseflanges. As will be observed in FIG. 3, when a fastener 24 is drivenagainst a side flange, such as flange 26, the flange will bend inwardonly slightly before it abuts the adjacent arm of bracing section 44which then provides lateral support to hold the flange in position fordriving of the fastener therethrough. If suflicient inward force isapplied the stud will be distorted until the opposite end of section 44abuts the other flange 30, thereby placing the end section 44 incompression between the side flanges and providing greater lateralsupport for flange 26, particularly when the flange 30 is secured to apanel or is otherwise supported. By reference to the flange 39 in FIG.3, it will be observed that when a fastener 24 is in its final seatedposition, the side flange is drawn outward into parallel face-to-facecontact with the adjacent surface of the board 22, thereby restoring theclearance between the flange and the end section 44. By thisarrangement, the truss elements 36 provide lateral support for the sideflanges 26 and 30 during application of the fasteners, and thereafter aclearance is provided between the truss elements and the flanges toavoid any noise problem such as might arise from the flanges and trusselements rubbing against one another during any slight movements of thepartition. These clearances also assist in minimizing sound transmissionthrough the finished partition construction. After the partition iscompleted, with the flanges secured to the wallboard panels, the studs20 assume the approximate strength characteristics of a box-type stud,and the reinforcing contribution of the truss elements 36 is no longernecessary.

Each truss element 36 is provided with a reinforcing flange 50 along endsection 44. Flange 50 is normal to the remainder of the truss elementand enhances the compressive strength of the bracing section 44extending between the side flanges.

The illustrated stud 20 may be formed of a unitary blank of formablesheet material, such as sheet metal, for instance sheet metal on theorder of 0.02" thick. This is perhaps best illustrated by reference tothe unitary blank 20', shown in FIG. 4. The dashed lines in this figureindicate the lines along which the blank will be bent or 4 folded informing the stud 2t and thus delineate the sec tions 23', 26, and 3%),32a, 32b, 34a and 34b which will form the web 28, side flanges 26 and 30and lip flanges 32a, 32b, 34a and 34b, respectively. Elements 36' arecut or struck from the central web portion 28 and are subsequently bentalong lines 38' in forming the truss elements 36. As can be readilyseen, each element 36' includes sections 40, 42 and 44, the latterincluding arm sections 46' and 48' and a flange forming section 50', forforming the corresponding parts of each truss element 36.

The stepped configuration of the truss elements 36 provides anadvantageous configuration of the openings which are provided in the web28 by the striking of the truss elements 36 therefrom, particularly whencombined with the removal of additional material as indicated by line52', directly opposite the base section, to form an opening 52. Thelower and narrower portion of each strike out corresponding to section40 forms an opening adapted to receive a relatively narrow channelmember passing through the stud 20, whereas the wider strike outcorresponding to section 42 permits passage of a wider channel member.These openings, in cooperation with the arcuate openings 52, permitpassage of sizeable round conduit such as illustrated at 53 in FIG. 1.It will also be observed that the openings are centrally located in theweb sections 28, being symmetrical about the center line of the blank26' and of the resulting structural element 20. The openings in web 28thus may accommodate conduit or other service elements, or reinforcingmembers such as are sometimes extended through aligned openings in aseries of studs in partition constructions.

FIGS. 5 through 13 illustrate various modifications of stud 20.Accordingly, for convenience, the same numerals will be applied tocorresponding elements in most instances.

FIGS. 5 and 5a illustrate a stud 20b including an interlockingconnection between the distal edge portions of the truss elements 36 andthe return flanges 34 of flanges 26 and 30. In this embodiment returnflanges 34a and 34!) are formed with notches 54 which receive endportions 56 of the reinforcing flange 50a (see FIG. 50). Each flange 56ais provided with a shoulder 58 at each end. The distance between theshoulders 58 of a flange Stla is equal to the desired spacing betweenreturn flanges 34, or slightly less than this distance to provideclearances between the trusses and side flanges as discussed aboveregarding stud 20. By providing the truss elements 36 of a length(measured normal to web 28) slightly greater than the distance betweenweb 28 and the opposed inner edges of return flanges 34, the portions 56may be caused to engage notches 54 with a snap action to facilitateproduction of this type of structural element. In an alternativeinterlocking arrangement of the trusses and side flanges, the shoulders58 may be eliminated and the notches 54 may be formed of a widthslightly greater than the depth of the reinforcing flange 50a wherebythe ends of arms 46 and 48 Will abut the inner iqulracis of flanges 26and 30 as in the embodiment of FIGS. 6 and 7 illustrate a stud 20cwherein each trussing element 60 is in the shape of a trapezoid. Eachelement 60 is joined to the web 28 along a bend line 62 and is providedwith a reinforcing flange 64 along its distal edge. The outermostsurface of the reinforcing flange 64 lies flush with the front surfacesof flange sections 32. The bracing edge section of truss element 60 thusextends between the inner surfaces of the return flanges 34, whereby thelateral bracing support for the side flanges is provided on the returnflanges. By providing the bracing edge section of truss element 60 of awidth to extend between flanges 34, the corresponding strike outs may besufliciently narrow to leave a substantial portion of web material ateach side of the strike out openings, as at 66 and 68, to provideadequate strength against deflection of the rear edges of flanges 26 and30 in this area. If desired, the distal portion of the truss element 60may be formed with slots 70 and 72 to receive the return flange portions34 whereby the flanges 26 and 30 are supported by the truss element 60against outward as well as against inward deflection.

FIGS. 8 and 8a illustrate a stud 20d including a truss element ofanother configuration and including another alternative interlockingarrangement between the truss element and the lip portions of the sideflanges. In this arrangement, the edge portions 34c and 34d of the sideflanges 26 and 30 are bent back parallel to the sections 32. Theportions 34c and 34d are cut away for short lengths to form notches 74,as illustrated in FIG. 8a, for receiving the reinforcing flange 76extending along the outer edge of the truss element 78.

In the studs 202 and 20 illustrated in FIGS. 9-12, each truss element isof a generally triangular configuration and provides lateral support fora single side flange of the stud.

Stud 202 (FIGS. 9 and incorporates alternate truss elements 80 and 82engaging, respectively, side flanges 26 and 30. The elements 30 and 82are identical except for being reversed with respect to one another asseen in FIG. 10. Each of these truss elements is joined to the web 28along a bend line 84 and has its apex disposed adjacent the innersurface of the distal edge portion of the respective side flange. Eachtruss element 80 and 82 is provided with a reinforcing flange 86 alongits distal edge. The bend line 84 and one side of each element 80 and 82define an obtuse angle, as best seen in FIG. 10, and each bend line 84extends at an angle of less than 90 to the plane of the respective sideflange. By this construction, adequate material may be left between thestrike out and the edge of web 28, as at 38, for support of the rearedge of the adjacent side flange, and the apex of the truss is disposedadjacent the respective side flange when the truss element is bent intoits flange supporting position as illustrated in FIGS. 9 and 10.

FIGS. 11 and 12 illustrate a stud 20] including pairs of oppositelydirected, generally triangular truss elements 90 and 92 formed fromcontiguous strike outs by utilizing a strike out pattern as shown inFIG. 13. The individual truss elements 90 and 92 are similar to thetruss elements 80 and 82 of FIGS. 9 and 10, except that the distal orapex ends of elements 90 and 92 are truncated to provide more extensivebearing areas with the side flanges 26 and 30. In FIG. 13, portions 90'and 92' identify the strike outs which form the respective trusselements 90 and 92 when bentabout lines 94 and 96' into flangesupporting positions. Lines 94 and 96 may extend at acute angles to therespective side flanges as described above regarding bend line 84 instud 202. Lines 98 and 100' indicate the bend lines for formingreinforcing flanges 102 and 104 from portions 102 and 104.

It will be appreciated that in the instance of each modification shown,an apropriate number of trussing elements may be provided in spacedrelation along the length of the structural elements 20. Reinforcingribs may be embossed in the various truss elements. In each embodimentclearances may be provided between the truss elements and the sideflanges, whereby the truss elements will provide the necessary supportfor the side flanges during assembly, as in fabrication of a wallboardpartition, but will thereafter remain free of these elements to avoidsqueaking and to minimize noise transmission through the resultingpartition. Interlocking designs may be utilized as illustrated in FIGS.5-8a, and may be designed to confine the side flanges against outwarddeflection as well as against inward deflection, for instance asillustrated in FIGS. 6 and 7. The distal edges of the truss elements maybe affixed to the side flanges for providing added rigidity of thestructural elements 20, if desired, as by crimping, spot welding, orother securing means, though this will add to the expense of production.

It will thus be seen that an improved structural member has beenprovided which includes support against deflection of the side flanges.Further, it will be appreciated that the trussing elements by which theimproved deflection strength is obtained may be formed by very simplemanufacturing processes, for instance by stamping or striking the trusselements from the web section and subsequently bending them intosupporting position. It will be found that these operations may beconveniently performed by machines in production lines operating atsubstantially the same speeds usually encountered in high speedproduction of simple channel type sheet metal structural elements.Accordingly, there is very little increase in cost of the structuralelements embodying this invention over simple channel-type structuralelements of corresponding size, weight and materials. Thus, the improvedstructural elements of this invention may be economically produced.

While particular embodiments of the invention have been shown, it willbe understood, of course, that this invention is not limited theretosince many modifications may be made by those skilled in the art,particularly in light of the foregoing teachings.

I claim:

1. An elongated structural member comprising a web, at least one flangeextending laterally from said web, and a plurality of truss elementsstruck from said web intermediate the ends of said member, said webbeing provided with an opening therethrough adjacent each of said trusselements, each of said truss elements extending laterally from said weband including a portion disposed adjacent a distal portion of saidflange to brace said flange, said truss elements being spaced. from oneanother longitudinally of said member to brace said flange oversubstantially the entire length of said member.

2. An elongated structural member as in claim 1 wherein each of saidtruss elements is spaced from said flange to provide clearance betweensaid flange and said truss elements except when said flange is pressedinward toward said truss elements.

3. An elongated structural member as in claim 1 wherein each of saidtruss elements includes a flange along its distal edge and a bodysection joined to said Web, each of said truss flanges extending at anangle to the respective truss body section to provide compressive loadstrength along the distal edges of said truss elements.

4. An elongated structural member as in claim 1 wherein each of saidtruss elements is of a generally triangular configuration, each of saidtruss elements being joined to said web along one side of such triangleand having its apex adjacent the distal portion of said flange.

5. An elongated structural member as in claim 1 wherein said portion ofeach of said truss elements is in interlocking engagement with thedistal edge portion of said flange.

-6. An elongated structural member as in claim 1 wherein said flangeincludes a lip portion extending along the distal edge thereof andformed with a plurality of notches, and each of said truss elements isengaged in one of said notches.

7. An elongated structural member as in claim 1 wherein each of saidtruss elements is formed With a notch in its distal edge, and saidflange is provided, along its distal edge, with a lip portion extendingtoward said web, said lip portion extending into said notch of saidtruss elements.

8. An elongated structural member as in claim 1 wherein each of saidtrusses is disposed in a plane normal to the plane defined by saidflange.

9. An elongated structural member formed of a blank of sheet materialand comprising a web, first and second flanges extending laterally fromsaid web, said flanges being integrally joined with opposite edges ofsaid Web whereby said web and said flanges define a channelshapedmember, first and second truss elements struck from said web and eachextending laterally therefrom, said first truss element including aportion disposed adjacent a distal portion of said first flange to bracesaid first flange, and said second truss element including a portiondisposed adjacent a distal portion of said second flange to brace saidsecond flange.

It). An elongated structural element as in claim 9 wherein each of saidtruss elements is of a generallyy triangular configuration and is joinedto said web along one side of such triangle, said truss elements beingformed in pairs from contiguous portions of said web, one truss elementof one pair bracing one of said flanges and the other truss element ofsuch pair bracing the other of said flanges.

11. An elongated structural member formed of a blank of sheet materialand comprising a web, first and second flanges extending laterally fromopposite edges of said web whereby said web and said flanges define achannelshaped member, and a .plurality of truss elements struck fromsaid web intermediate the ends of said member, said web being providedwith an opening therethrough adjacent each of said truss elements, eachof said truss elements extending laterally from said web and including aportion disposed adjacent a distal portion of said first flange and aportion disposed adjacent a distal portion of said second flange tobrace said flanges, said truss elements being spaced from one anotherlongitudinally of said member to brace said flanges over substantiallythe entire length of said member.

12. An elongated structural element as in claim 11 wherein each of saidtruss elements includes a base section joined to said web and a distalend section including said portions extending adjacent said flanges,each of said truss elements being disposed centrally of said web andbeing of less width than said web.

13. An elongated structural member as in claim 12 wherein each of saidbase sections is of stepped configuration and includes a first portionjoined to said web and a portion wider than said first portion andnarrower than said end section.

14. An elongated structural member as in claim 13 wherein said web isprovided with an opening of a configuration conforming, in part, to theoutline of said base section.

15. An elongated structural member as in claim 9 wherein each of saidtruss elements includes portions disposed adjacent distal portions ofeach of said flanges.

References Cited UNITED STATES PATENTS 1,495,943 5/1924 Wiley 2482482,048,153 7/1936 Wollaeger 52 243 X 3,243,930 4/1966 Slowinski 52-732 X3,320,710 5/1967 Byssing 52-735 BOBBY R. GAY, Primary Examiner A. M.CALVERT, Assistant Examiner US. Cl. X.R.

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